Related Manuals for KTM 125 ECX EU
Summary of Contents for KTM 125 ECX EU
- Page 1 OWNER'S MANUAL 2012 125 EXC EU 125 EXC SIX DAYS EU 200 EXC EU 200 EXC AUS 200 XC‑W USA 250 EXC EU 250 EXC AUS 250 EXC SIX DAYS EU 250 XC‑W USA 300 EXC EU 300 EXC AUS 300 EXC SIX DAYS EU 300 XC‑W USA Art.
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Preparations for riding on wet sand ......... 27 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........5 Preparations for riding on wet and muddy surfaces ... 28 IMPORTANT INFORMATION ..........6 Preparations for riding at high temperatures and low VIEW OF VEHICLE............... - Page 5 TABLE OF CONTENTS Removing the seat ............55 Removing the headlight mask with the headlight (All EXC models) ................ 85 Mounting the seat ............55 Refitting the headlight mask with the headlight (All EXC Removing the air filter box lid......... 56 models) ................
- Page 6 TABLE OF CONTENTS Carburetor configuration (All 200 models) ....115 Carburetor configuration (All 250 models) ....116 Carburetor configuration (All 300 models) ....117 General carburetor configuration ......118 TECHNICAL DATA - CHASSIS .......... 119 Lighting equipment ............. 120 Tires ................120 Capacity - fuel.............
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. -
Page 8: Important Information
Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. - Page 9 IMPORTANT INFORMATION Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. –...
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Page 10: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) B00784-10 Hand brake lever ( p. 12) Kill switch ( p. 12) Clutch lever ( p. 12) Air filter box lid Fuel tap ( p. 21) Chain guide Side stand ( p. -
Page 11: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) B00783-10 Filler cap Bleeder screw, fork leg Throttle grip ( p. 12) Chassis number ( p. 10) Kickstarter ( p. 22) Foot brake lever ( p. 23) Shock absorber, compression adjustment Level viewer, rear brake fluid Shock absorber, rebound adjustment... -
Page 12: Serial Numbers
SERIAL NUMBERS Chassis number (XC-W) The chassis number is stamped on the right side of the steering head. B00015-10 (All EXC models) The chassis number is stamped on the right side of the steering head. 303438-10 Type label (XC-W) The type label is fixed to the front of the steering head. -
Page 13: Engine Number
SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket. B00016-10 Fork part number The fork part number is stamped on the inner side of the fork stub. B00265-01 Shock absorber part number The shock absorber part number... -
Page 14: Controls
CONTROLS Clutch lever (All 125/200 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B00001-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. ... -
Page 15: Short Circuit Button (Xc-W)
CONTROLS Short circuit button (XC-W) Short circuit button is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition circuit is • Short circuit button closed, and the engine can be started. pressed –... -
Page 16: Emergency Off Switch (250/300 Exc Aus)
CONTROLS Emergency OFF switch (250/300 EXC AUS) 5.10 The emergency OFF switch is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a run- ning engine stops, and a non-running engine will not start. Ignition on –... -
Page 17: Speedometer
CONTROLS Speedometer 5.15 – Press the button to change the display mode or change to one of the Setup menus. – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. -
Page 18: Setting The Clock
CONTROLS – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. -
Page 19: Querying Lap Time
CONTROLS Info If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed. Querying lap time 5.21 Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary. -
Page 20: Display Mode Speed/Clk (Clock)
CONTROLS Display mode SPEED/CLK (clock) 5.24 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button . -
Page 21: Display Mode Speed/Tr2 (Trip Master 2)
CONTROLS Display mode SPEED/TR2 (trip master 2) 5.28 – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button . -
Page 22: Display Mode Speed/S1 (Stop Watch 1)
CONTROLS Display mode SPEED/S1 (stop watch 1) 5.31 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor. -
Page 23: Fuel Tap
CONTROLS Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) • Display mode SPEED/A1 (average speed 1) •... -
Page 24: Closing The Filler Cap
CONTROLS – Press release button , turn the filler cap counterclockwise and lift it free. 303520-10 Closing the filler cap 5.35 – Replace the filler cap and turn clockwise until the release button locks in place. Info Run the fuel tank breather hose without kinks. -
Page 25: Foot Brake Lever
CONTROLS Foot brake lever 5.38 Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. B00788-10 Side stand 5.39 The side stand is on the left side of the vehicle. ... -
Page 26: Unlocking The Steering (All Exc Models)
CONTROLS Unlocking the steering (All EXC models) 5.42 – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. -
Page 27: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 28: Running In The Engine
PREPARING FOR USE – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. -
Page 29: Preparations For Riding On Dry Sand
– Mount the dust cover for the air filter. Dust cover for air filter (59006019000) Info Read the KTM PowerParts installation instructions. 600869-01 – Mount the dust cover for the air filter for sand. Sand cover for air filter (59006022000) Info Read the KTM PowerParts installation instructions. -
Page 30: Preparations For Riding On Wet And Muddy Surfaces
Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Mount the steel sprocket. – Clean the motorcycle. ( p. 101) –... -
Page 31: Preparing For Rides At Low Temperatures Or In Snow
Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop. -
Page 32: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 98) –... -
Page 33: Start Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 34: Stopping, Parking
RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. –... - Page 35 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 9.5 l Super unleaded gasoline, mixed with capacity, approx. (2.51 US gal) 2-stroke engine oil (1:60) ( p.
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Page 36: Service Schedule
• Final check: Check the vehicle for safe operation and take a test ride. • • Make the service entry in KTM DEALER.NET and in the service record. • • S20A: Every 20 operating hours S40A: Every 40 operating hours/after every race... -
Page 37: Maintenance Work (As An Additional Order)
SERVICE SCHEDULE Maintenance work (as an additional order) S10N S40A S80A • Change the front brake fluid. Change the rear brake fluid. • Change the foot brake cylinder seals. • Change the hydraulic clutch fluid. p. 67) • Grease the steering head bearing. p. -
Page 38: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 39: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 40: Measuring The Sag Of The Unloaded Rear Wheel
TUNING THE CHASSIS – Turn adjusting screw clockwise with a screwdriver to the last click. Info Do not loosen nut – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) Rebound damping B00792-10 Comfort... -
Page 41: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 42: Adjusting The Riding Sag
TUNING THE CHASSIS – Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) – Install the shock absorber. p. 54) Adjusting the riding sag 9.10 – Remove the shock absorber. p. 54) – After removing the shock absorber, clean it thoroughly. –... -
Page 43: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS Adjusting the compression damping of the fork 9.12 Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection covers – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. ... -
Page 44: Adjusting The Spring Preload Of The Fork
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Adjusting the spring preload of the fork 9.14 – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. –... - Page 45 TUNING THE CHASSIS – Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it 0 0 1 0 0 1 to one side. 0 0 2 0 0 2 Info Protect the motorcycle and its attachments against damage by covering them.
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Page 46: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS Raising the motorcycle with the lift stand 10.1 (All 125/200 models) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. -
Page 47: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS (All EXC models) – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. 303391-10 (XC-W) – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. –... -
Page 48: Positioning The Fork Protection
SERVICE WORK ON THE CHASSIS Positioning the fork protection 10.6 – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line. Position the clamp and mount and tighten screws ... -
Page 49: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS (XC-W) – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws toward the front. 303391-10 (EXC EU/AUS, XC‑W) –... -
Page 50: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS Installing the fork protector 10.10 – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 51: Installing The Lower Triple Clamp (Exc Eu/Aus, Xc-W)
SERVICE WORK ON THE CHASSIS Installing the lower triple clamp (EXC EU/AUS, XC‑W) 10.13 – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 128) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 52: Installing The Lower Triple Clamp (Exc Six Days)
SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) B00810-11 – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) B00799-13 – Position the brake caliper. Mount and tighten screws ... - Page 53 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the steering. – Mount screw but do not tighten yet. – Position the clutch line and wiring harness. B00807-11 – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp.
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Page 54: Checking The Play Of The Steering Head Bearing
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 55: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS (EXC SIX DAYS) – Loosen screws . Remove screw – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. –... -
Page 56: Removing The Front Fender
SERVICE WORK ON THE CHASSIS Removing the front fender 10.20 – Remove screws . Remove the front fender. – Make sure the spacers remain in place. B00814-10 Installing the front fender 10.21 – Ensure that the spacers are mounted in the fender. –... -
Page 57: Removing The Seat
SERVICE WORK ON THE CHASSIS Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life. -
Page 58: Removing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS Removing the air filter box lid 10.26 – Pull off the air filter box lid in area sideways and remove it toward the front. B00819-10 Installing the air filter box lid 10.27 – Insert the air filter box lid into the rear area and clip it into the front area ... -
Page 59: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS – Put in both parts together, position them, and fix them with air filter holder Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. –... -
Page 60: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS Installing the main silencer 10.32 – Mount the main silencer with rubber sleeve – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B00821-11 Changing the glass fiber yarn filling of the main silencer 10.33 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. -
Page 61: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Turn handle of the fuel tap to the OFF position. (Figure 601157-10 p. 21) – Pull off the fuel hose. Info Remaining fuel may run out of the fuel hose. – Remove screws with the collar sleeve. -
Page 62: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS – Mount the fuel tank vent hose. – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) (All EXC models) – Position the horn with the horn bracket. B00822-11 –... -
Page 63: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Checking the chain tension 10.38 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. - Page 64 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) 0 0 A – Measure the distance of 18 chain links in the lower chain section. ...
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Page 65: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –... -
Page 66: Adjusting The Chain Guide
SERVICE WORK ON THE CHASSIS – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws to the left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws on the left and right so that the markings on the left ... -
Page 67: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401347-01 Checking the swingarm 10.43 –... -
Page 68: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS (All 250/300 models) – Check the throttle cable routing. The throttle cable must be routed to the carburetor on the left side of the upper frame tube behind the handlebars. » If the throttle cable is not routed as specified: –... -
Page 69: Checking The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS (All 250/300 models) – Adjust the basic setting of the clutch lever to your hand size by turning adjust- ing screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. - Page 70 SERVICE WORK ON THE CHASSIS (All 125/200 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Remove screws – Remove cover with membrane 400245-10 – Fill bleeding syringe with the appropriate hydraulic fluid. ...
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Page 71: Brakes
BRAKES Checking free travel of hand brake lever 11.1 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating. -
Page 72: Checking The Brake Discs
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 73: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 74: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 75: Checking The Free Travel Of Foot Brake Lever
BRAKES – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 0 0 6 100397-01 – Fit the brake linings, insert the bolt, and mount the locking split pins. –... -
Page 76: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 77: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 78: Installing The Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. - Page 79 BRAKES – Remove the rear brake linings. p. 75) – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
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Page 80: Wheels, Tires
WHEELS, TIRES Removing the front wheel 12.1 – Raise the motorcycle with the lift stand. ( p. 44) – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. -
Page 81: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against on the brake disc. -
Page 82: Checking The Tire Condition
12.5 Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 83: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 84 WHEELS, TIRES Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 85: Electrical System
ELECTRICAL SYSTEM Removing the battery (All 250/300 models) 13.1 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 86: Changing The Main Fuse (All 250/300 Models)
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 87: Removing The Headlight Mask With The Headlight (All Exc Models)
ELECTRICAL SYSTEM – Remove screw 101395-10 – Lift rear fairing slightly and pull starter relay out of the bracket. 101396-10 – Remove the protection caps. – Remove the faulty main fuse Info A defective fuse is indicated by a burned-out fuse wire ... -
Page 88: Refitting The Headlight Mask With The Headlight (All Exc Models)
ELECTRICAL SYSTEM Refitting the headlight mask with the headlight (All EXC models) 13.6 – Connect the electric plug connector 303402-11 – Position the headlight mask and fix it with the rubber band Info Ensure that the holding lugs engage in the fender. –... -
Page 89: Checking The Headlight Setting (All Exc Models)
ELECTRICAL SYSTEM Checking the headlight setting (All EXC models) 13.8 – Position the vehicle upright on a horizontal surface in front of a light wall and make 0 0 A a mark at the height of the center of the low beam headlight. –... - Page 90 ELECTRICAL SYSTEM – Position locking cap and turn it clockwise all the way using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with the washers. (All EXC models) –...
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Page 91: Cooling System
COOLING SYSTEM Cooling system 14.1 (All 125/200 models) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified ... -
Page 92: Checking The Coolant Level
COOLING SYSTEM Checking the coolant level 14.3 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 93: Refilling With Coolant
COOLING SYSTEM (All 250/300 models) – Remove screw . Remove radiator cap – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) B00835-11 Refilling with coolant... - Page 94 COOLING SYSTEM – Fill the radiator completely with coolant. – Mount radiator cap – Run the engine until it is warm. – Check the coolant level. ( p. 90) B00836-10...
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Page 95: Tuning The Engine
TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 96: Carburetor - Adjusting The Idle Speed
TUNING THE ENGINE Idle air range A 0 0 0 D Operation with the throttle slide closed. This range is influenced by adjusting screw and the idle air adjusting screw Transition range B 0 0 C Behavior of the engine when the throttle slide is being opened. This range is influenced by the idling jet and by the form of the throttle slide. -
Page 97: Emptying The Carburetor Float Chamber
TUNING THE ENGINE – Turn idle air adjusting screw slowly in a clockwise direction until the idle speed begins to fall. – Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed falls again. –... -
Page 98: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE Checking the basic position of the shift lever 15.6 – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…... - Page 99 TUNING THE ENGINE – Remove screws B00057-10 – Take locking cap , adjusting spring , auxiliary spring and spring insert 0 0 2 of the clutch cover. – Pull both springs off of the spring insert. 0 0 3 0 0 0 4 0 0 5...
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Page 100: Service Work On The Engine
SERVICE WORK ON THE ENGINE Checking the gear oil level 16.1 Info The gear oil level must be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. (All 125/200 models) – Remove gear oil level check screw ... -
Page 101: Draining The Gear Oil
SERVICE WORK ON THE ENGINE Draining the gear oil 16.3 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 102: Adding Gear Oil
SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. -
Page 103: Cleaning, Care
CLEANING, CARE Cleaning the motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 104: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE Checks and maintenance steps for winter operation 17.2 Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against the aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 105: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 44) – Cover the vehicle with a tarp or cover that is permeable to air. -
Page 106: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 30) (All 250/300 models) – Battery discharged Recharge the battery. p. 83) – Check the charging voltage. –... - Page 107 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Lack of fuel Turn handle of the fuel tap to the ON posi- carburetor tion. – Refuel. ( p. 32) – Engine takes in bad air Check the intake flange and carburetor for tightness.
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Page 108: Technical Data - Engine
TECHNICAL DATA - ENGINE 125 EXC EU, 125 EXC SIX DAYS EU 20.1 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing... -
Page 109: All 250 Models
TECHNICAL DATA - ENGINE 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter All 250 models... -
Page 110: Capacity - Transmission Oil
TECHNICAL DATA - ENGINE Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 rectangular rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48.5 mm (1.909 in) Primary transmission 26:72... -
Page 111: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES All 125/200 models 21.1 ® Screw, membrane 2 Nm (1.5 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, alternator cover 5 Nm (3.7 lbf ft) ®... -
Page 112: All 250/300 Models
TECHNICAL DATA - ENGINE TIGHTENING TORQUES All 250/300 models 21.2 ® Screw, angle lever, exhaust control 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, exhaust control cover 6 Nm (4.4 lbf ft) ® Screw, ignition pulse generator 6 Nm (4.4 lbf ft) Loctite 243™... -
Page 113: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 125 EXC EU, 125 EXC SIX DAYS EU 22.1 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (NOZF / NOZG / NOZH) Main jet 100 (168/170/172) Idling jet 38X38 (45) Starting jet... -
Page 114: 250 Exc Eu, 250 Exc Six Days Eu
TECHNICAL DATA - CARBURETOR 250 EXC EU, 250 EXC SIX DAYS EU 22.5 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K (N8RW / N8RJ / N8RK) Main jet 110 (162/165) Idling jet 38X38 (35) Starting jet... -
Page 115: 300 Exc Aus
TECHNICAL DATA - CARBURETOR 300 EXC AUS 22.9 Carburetor type KEIHIN PWK 36S AG Carburetor identification number 3600C Needle position 1st position from top Jet needle N3CJ (N8RW / N8RJ / N8RK / N2ZK / N2ZJ / N2ZL) Main jet 160 (162/165) Idling jet Starting jet... - Page 116 TECHNICAL DATA - CARBURETOR 401348-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces!
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Page 117: Carburetor Configuration (All 200 Models)
TECHNICAL DATA - CARBURETOR Carburetor configuration (All 200 models) 22.12 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 401042-01 M/FT ASL Sea level... -
Page 118: Carburetor Configuration (All 250 Models)
TECHNICAL DATA - CARBURETOR Carburetor configuration (All 250 models) 22.13 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 401043-01 M/FT ASL Sea level... -
Page 119: Carburetor Configuration (All 300 Models)
TECHNICAL DATA - CARBURETOR Carburetor configuration (All 300 models) 22.14 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 401044-01 M/FT ASL Sea level... -
Page 120: General Carburetor Configuration
TECHNICAL DATA - CARBURETOR General carburetor configuration 22.15 1... 5 Needle position from above The five needle positions are shown here. 0 0 1 The carburetor configuration depends on the defined ambient and operating conditions. 0 0 2 0 0 3 0 0 4 0 0 5 B00075-10... -
Page 121: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 22 mm (0.87 in) Shock absorber WP Suspension PDS 5018 DCC Brake system... -
Page 122: Lighting Equipment
80/100 - 21 51M TT 110/100 - 18 64M TT Dunlop GEOMAX MX 51 Dunlop GEOMAX MX 51 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) approx. -
Page 123: Technical Data - Fork
TECHNICAL DATA - FORK All 125/200 models 24.1 Fork part number 14.18.7L.61 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Full payload 20 clicks Rebound damping Comfort 22 clicks Standard 20 clicks Sport... - Page 124 TECHNICAL DATA - FORK Weight of rider: 85… 95 kg (187… 209 lb.) 513 mm (20.2 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85…...
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Page 125: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER All 125/200 models 25.1 Shock absorber part number 12.18.7L.61 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard... - Page 126 TECHNICAL DATA - SHOCK ABSORBER Spring preload Comfort 7 mm (0.28 in) Standard 7 mm (0.28 in) Sport 7 mm (0.28 in) Full payload 8 mm (0.31 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75…...
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Page 127: Technical Data - Tightening Torques For Chassis
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal 2.5 Nm (1.84 lbf ft) (All 250/300 models) – Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) –... -
Page 128: Substances
2-stroke engine oil According to – JASO FC ( p. 130) Guideline – ® Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex products. Fully synthetic Supplier ® Motorex – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to –... - Page 129 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
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Page 130: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –... - Page 131 AUXILIARY SUBSTANCES Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Synthetic...
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Page 132: Standards
STANDARDS JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles –... -
Page 133: Index
INDEX Compression damping INDEX fork, adjusting ......41 Accessories ........6 Compression damping, high-speed Air filter shock absorber, adjusting . - Page 134 INDEX Frame installing ....... . . 58 checking ....... . . 65 removing .
- Page 135 INDEX Start number plate installing ....... . . 53 removing ....... . . 53 Starting .
- Page 136 *3211718en* 3211718en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...